SHEAR GENIUS®

BY FINN-POWER

PUNCHING

LASER CUTTING

BENDING

INTEGRATED PUNCHING & LASER CUTTING

FLEXIBLE MANUFACTURING SYSTEMS

INTEGRATED PUNCHING & SHEARING

SHEAR GENIUS®

BY FINN-POWER

2

FINN-POWER's new Shear Genius® provides

more capacity, quality and cost-efficiency for

flexible sheet metal working than any compara-

ble system.

Twenty years of experience in right angle

shear technology combined with proven field

performance in nearly 2,000 applications

throughout the world has allowed FINN-

POWER to provide a new Shear Genius® with

these benefits:

- flexible automated fabrication

- savings in raw material

- higher productivity

- reduced manufacturing costs

- faster return on investment

The Shear Genius® provides the competitive

edge for today's demanding business environ-

ment.

3

LOADING

PROGRAMMING

PUNCHING

SHEARING

The Shear Genius® philosophy

The Shear Genius® philosophy is to provide one

machine capable of transforming a full sized

sheet into finished parts with scrap separated.

These parts can be moved to final production

stages without the need for secondary opera-

tions for costly material handling between load-

ing, punching, shearing, sorting and unloading.

With Shear Genius® you can use pre-cut sheets,

but normally standard size sheets are pro-

cessed while major savings are achieved through

efficient nesting.

No other manufacturer approaches FINN-

POWER's expertise in integrated right angle

shear technology. This core competence enabled

us to engineer new, productive features into

a proven concept for increased productivity and

material savings.

By combining several work stages into an auto-

mated process, the Shear Genius® concept

saves material, eliminates manual handling, de-

creases necessary floor space and investment

in separate machine tools, tooling and energy.

Welcome to the new Shear Genius® benefits.

Reliability & manufacturing economy

based on experience

THE COST CUTTING SOLUTION

FOR HIGH-QUALITY FABRICATION

4

The vast majority of all fabricated sheet metal

components are rectangular. Also, parts with

two or three straight edges are perfect for

fabrication with a right angle shear.

Today, right angle shear technology is used

throughout the industrial world in most varied

applications, as independent production cells,

or as central units within automatic material

handling systems up to a factory-wide FMS

level.

Here are some of the reasons why:

Pre-shearing is a waste of time and money.

Moreover, it is extremely difficult for a stand

alone shear to achieve anything like the accuracy

of components manufactured by an integrated

right angle shear. FINN-POWER's right angle

shear has two blades mounted at a 90º angle.

1) Avoiding the cost of pre-shearing

One stroke detaches one or several compo-

nents.

Micro jointed or nibbled components often re-

quire an additional work stage, such as de-

burring, to improve edge quality. A right angle

shear produces sufficiently high edge quality for

practically every purpose. The component is usu-

ally ready for the next work stage as it unloads

from the machine. For example, there is no oxide

layer on the edges to be removed before painting.

As for consumables, FINN-POWER's right angle

shear technology uses only energy and com-

pressed air. The blades have several cutting

edges – enough for years of production with an

occasional sharpening. Blades, like punching

tools, can be sharpened numerous times.

2) Just the right edge quality

3) Practically no consumables

5

Integratedright angle shear for

more parts

better parts

at a lower cost

4) Don't pay for material you don't need

5) Automated solution

Modern production planning and automatic

nesting software allow optimizing the use of

raw material – a significant cost item in the

production of sheet metal products. Compared

with traditional methods, an integrated right

angle shear can save significant raw material

costs.

The Shear Genius® method makes maximum

use of material and eliminates micro-jointed

parts and further manual operations.

Shear Genius® automates loading, punching &

shearing with secondary work stages, as well

as component exit. It eliminates manual separa-

tion of micro-jointed parts. The modular de-

sign of the Shear Genius® allows the addition

of sorting and stacking equipment after the ini-

tial installation. With material handling equip-

ment, sorting and stacking can be reliably auto-

mated.

The reliability of shearing and automatic compo-

nent removal are inherent benefits of the right

angle shear concept, and make Shear Genius®

the optimum machine tool for high-level automa-

tion and unmanned operation.

Shear Genius®

FINN-POWER's basic Shear Genius® package con-

sists of

There are two Shear Genius® models for stan-

dard size sheets (max.)

SG6: 3,074 mm x 1,565 mm (120" x 60" )

SG8: 4,300 mm x 1,565 mm (170" x 60" )

-

-

-

Automatic loading equipment

300 kN (33 US ton) hydraulic turret punch

press with capacity up to 200 tools

Integrated right angle shear

FINN-POWER PUNCHING

FEATURES

6

Up to 200 tools

Fast auto index system

The turret layout is cus-

tomer-specific. Various

tool holder sizes can

be changed or switched

from station to station.

Any major tooling style

can be chosen, and you

can often use your exist-

ing tooling. Additional

index stations can be

added up to 10 (optional).

Multi-Tool® allows the

astonishing versatility of

200 tools simultaneously

in the turret, with both

indexable and fixed Multi-Tools® available.

Up to 10 large index stations (88.9 mm / 3.5")

and even 80 indexable tools with R Multi-Tools®

can be installed.

The fast auto-index system is based on an AC

servo motor; the rotation mechanism of the

punch and die is mechanically engaged and disen-

gaged vertically. Tool rotation can be pro-

grammed in 0.001° increments and throughout

the 360° rotation. The system automatically

selects the shorter path to desired angle.

MultiTool®

6 x A size

Index Tool,

89 mm max.Ø

51 mm max.Ø

51 mm max.Ø

51 mm max.Ø51 mm max.Ø

51 mm max.Ø

51 mm max.Ø

51 mm max.Ø

51 mm max.Ø 51 mm max.Ø

51 mm max.Ø

MultiTool®

10 x 16 mm max.Ø

Index tool,

max. 89 mmØ

MultiTool®

24 x max. 8 mmØ

Index Tool

3 x B size

Index Tool

max. 89 mmØ

Index Tool

max. 89 mmØ

MultiTool®

8 x 24 mm max.Ø

Index Tool

max. 89 mm

/ 16 mm indexable forming

Ø

Full tonnage and punch speeds can be used in

any station, with any tool size.

Both the turret punch press and the right angle

shear frame have been redesigned for additional

rigidity to accommodate the forces due to in-

creased speed and performance.

A full 300 kN (33 US ton) punching force is

available, with nibbling speed on 1 mm centers

up to 1,100 hits per minute. Digitally-servo-con-

trolled ram stroke speed is fully and individually

adjustable in both directions. Other benefits

include the availability of different punching

modes (punch, slow punch, downforming and

marking). For marking, punching speed up to

3,000 hpm can be achieved.

FINN-POWER's digital servo hydraulic punching

system provides the greatest flexibility for all

kinds of punching, forming and special applica-

tions, in one system.

Solid engineering

Hydraulics

Example of a customer specific turret layout. This one includes 66 tools,

of which seven index tools and one indexable high-forming station.

7

Automatic clamp setting and moving

Indexable upforming

Tapping

Part removal

FINN-POWER's patented programmable clamp

setting (PCS) is a standard SG feature. It auto-

matically positions sheet clamps via the NC

program. The possibility of punching or shearing

the clamps is eliminated and clamps are always

optimally placed.

When part programs are changed in an auto-

matic work queue, clamp settings change auto-

matically.

Dead zones can be completely eliminated by

using individual one clamp move while the other

clamps hold the sheet. This allows 100 % utiliza-

tion of the material without compromising accu-

racy. Better support for thin materials can be

achieved with optional 4th clamp.

The safe and natural solution for sheet metal

forming is from below the sheet. Using a hydrau-

lically actuated die holder and die movement, the

common hazards caused by conventional, high

forming dies – scratching of the sheet, colli-

sions, bending of the components during punch-

ing etc. – are eliminated.

With indexing possibilities the sheet can be uti-

lized more effectively, with reduced tooling cost,

as readily available standard formiong tools can

be used.

With the optional upforming unit, versatile forms

up to 16 mm (0.63") in height (incl. sheet thick-

ness) can be made.

FINN-POWER options can be added to increase

the number of work stages that Shear Genius®

can perform, thus eliminating the need for sepa-

rate machines and manual work stages.

A six-station servo driven tapping unit (option)

can be installed for extensive threading capaci-

ty. Alternatively, a one-station unit utilizing the

fast index system and accurate ram control is

available.

Component exit up to size 500 mm x 500 mm

(20" x 20") can also be arranged through a large

work chute (option). For example, instead of

destroying large rectangular cut-outs with a

square tool, a much faster solution is to use a

slitting or shearing tool and remove the pieces

through the chute. They can be slid into a small

box or removed with a conveyor to a pallet.

MORE THAN THE SUM

OF ITS MODULES

8

FINN-POWER's new Shear Genius® is designed

and built for maximum accuracy and manufac-

turing speed for optimum productivity.

The frame construction is extremely robust to

meet the requirements of very high axis speeds

and acceleration rates.

The combination of a 3,144 mm (123") long work-

ing area and the extremely high positioning

speed allowed by rack and pinion drives means

that more functions – punching, forming, tap-

ping, bar coding, and shearing – can be per-

formed flexibly as a single, multi-purpose work

Multi-function manufacturing solution

stage and in a single setup. This means that the

range of components that can be produced on

one and the same equipment is truly vast.

The working area and X carriage allow punching

or shearing of a full 3,000 mm (120") sheet

with a single clamping. Working area for shear-

ing is 4,144 mm (163").

A rack & pinion system actuates the X move-

ment direct from the motor with a gear mecha-

nism without belts. The solution allows high

acceleration and speeds. To guarantee high posi-

tion speed and acceleration, Y axis movement is

made by double ball screw.

Loading and squaring

Shear Genius® features fast, electric motor

and inverter driven loading for sheets up to

200 kg (440 lbs). Double sheet checking and

sheet measuring as well as squaring func-

tions are integrated in the gripper mechanism.

Squaring takes place on the machine table

and can be selected on or off depending on

stack quality.

FINN-POWER's design and the new up-and down

clamp movement allow convenient manual load-

ing of even small sheets. Manual unloading also

takes place in the same position at the table

edge.

9

Outstanding, accuracy

Shear Genius® accuracy reaches new levels

through a totally new actuation mechanism for

X and Y movement of the coordinate table. All

machines have to pass the FINN-POWER facto-

ry test before delivery.

Complete range of options

A well-known FINN-POWER strength is

the wide range of optional equipment,

using which a Shear Genius® can be cus-

tomized to meet specific production

requirements.

Only some of these options have been

described in this publication. FINN-

POWER sales engineers will give you

detailed information on e.g.

- material storages

- loading and unloading table alternatives

- E-stations for cluster tools

- Indexable Multi-Tools®

- integrated inkjet marking

- scrap removal

- cooling solutions for high ambient

temperatures

- CE safety

- Teleservice, etc.

The intelligent right angle shear

FINN-POWER's new right angle shear is extrem-

ely fast in operation.

Programmable blade height and automatic

stroke depth adjustment combine to allow

shearing speed up to 110 m/min (72.16"/s). In

the right angle shear, sheet holders are pro-

grammable, allowing shearing close to forms.

Blade speed is automatically selected for

the maximum speed. Together with automatic

shearing modes this optimizes operation

speed.

The intelligent right angle shear always allows

using the optimum solution for the stroke

according to the part size to be made in each

case, e.g.

- a single stroke for shearing a

1,000 mm x 1,500 mm (39.37" x 59.06")

- fast, multiple strokes in X direction

up to maximum sheet length

- fast cut mode for shearing

smaller components

Programmable, pneumatic sheet holders keep

the sheet stationary during the shearing pro-

cess. A sheet support mechanism ensures

stability and accuracy when large components

are sheared.

Blade clearance adjustment is automatic. The

right angle shear can be used for 0.5...4 mm

(0.02"...0.157") mild steel (aluminium up to

5 mm / 0.197") . For stainless steel max. thick-

ness is 3 mm (0.12").

10

FEATURES FOR FLEXIBLE

PRODUCTIVITY

Simple maintenance

Sophisticated programming systems

All machine tools require maintenance. The

search for compact constructions has often

lead to technical solutions where service points

are hard to reach. Shear Genius® features fast,

easy and safe access to service points, most of

which are located in a single cabinet.

Shear Genius® is equipped with central lubrica-

tion system to reduce maintenance times.

FINN-POWER's software range includes solu-

tions up to every level, including the optional

factory-wide software for production planning,

control and supervision.

Software for easy operation

FINN-POWER's Windows® based PowerLink cell

control allows unattended running of an auto-

matic work queues, even up to 24-hour unman-

ned operation.

FINN-POWER's ControlLink software is a user

interface for operating all machine functions. It

features user-friendly diagnostics, interactive

electrical drawings, full machine manuals, spare

part library, etc.

11

A

M

M

A

A A

A

Sheet loading

Part unloading

A = Automatic

M = Manual

Flexible material handling solutions

– integration

The construction is compatible with the whole

FINN-POWER range of optional modular material

handling equipment for sorting and stacking.

Thus Shear Genius® solutions can automate

- material storage with automatic feed

- loading with possibility of material change

during machine operation

- component exit

- scrap removal (punching and shearing)

- sorting and stacking of components

Shear Genius® technology is optimal for integra-

tion with subsequent bending by an automatic

FINN-POWER bending cell. FINN-POWER

PSBB processes blank sheets into bent

components on a compact line, while

Night Train FMS® provides fac-

tory-wide solutions for fully

automatic fabrication.

Finland

P.O. Box 38FI-62201 KauhavaFINLANDTel. + 358 6 428 2111Fax + 358 6 428 2083

Finn-Power Oy

Finn-Power Oy

P.O. Box 38FI-62201 KauhavaFINLANDTel. + 358 6 428 2111Fax + 358 6 428 2244www.finn-power.com

Germany

Lilienthalstr. 2 aIsar-Büro-ParkD-85399 HallbergmoosGERMANYTel. + 49 811 55330Fax + 49 811 1667

Finn-Power GmbH

Spain

Ctra. Molins de Rei-Rubí,km. 13,5 Nave 508191 – RUBÍ (Barcelona)SPAINTel. +34 902 302 111Fax +34 902 302 112

Finn-Power Iberica, S.L.

China

1/F, Block 1,Golden Dragon Ind. Centre152-160 Tai Lin Pai RoadKwai Chung, N.T.Hong Kong, P.R. CHINATel. + 852 2427 7991Fax + 852 2487 5548

FINN-POWER

Representative Office

United States

710 Remington Road,Schaumburg, IL 60173USATel. + 1 847 885 3200Fax + 1 847 885 9692

Finn-Power International, Inc.

Italy

Headquarters & Production

Viale Finlandia, 237044 Cologna Veneta (VR)ITALYTel. +39 0442 413111Fax +39 0442 413199

Sales & Service

Via Denti, 3825020 Cadimarco di Fiesse (BS)ITALYTel. +39 030 9506311Fax +39 030 9506340

Finn Power Italia srl

Finn Power Italia srl

France

13, avenue Condorcet,F-91240 St Michel-sur-OrgeFRANCETél. + 33 1 69 46 55 80Fax + 33 1 69 46 55 81

Finn-Power S.A.R.L.

Benelux

Leenstraat 5B-9810 Eke-NazarethBELGIUMTel. + 32 9 382 9030Fax + 32 9 382 9031

Finn-Power N.V.

Canada

1040 Martingrove Road, Unit 11Toronto, OntarioM9W 4W4CANADATel. +1 416 242 4431Fax +1 416 242 7867

Finn-Power Canada, Ltd.

FINN-POWER GROUP

Global Headquarters &Manufacturing

Sales & Service Units

For world-wide FINN-POWERsales & service representation,see www.finn-power.com

FINN-POWER, Combi FMS, Bendcam, Bendterm, Ecobend, Ecocut, Ecopunch,

Express, ISC, Multi-Tool, NC Express, Night Train FMS, Shear Genius and Shear

Brilliance are registered trademarks. All other product names identified through-

out this publication are trademarks or registered trademarks of their respective

owners.

The photography and line art shown throughout this brochure may not be

indicative of the final product. Equipment and equipment design is subject to

change without notice. Safety devices have been removed from photography

and line art for layout purposes.

Flexibly yours®

Item

1125

//SHEAR

GENIU

S®

//©

Finn-P

ower

Oy,11.2

007